HVAC door decelerator system with reduced noise

ABSTRACT

The present invention relates to an automotive HVAC door decelerator system which essential eliminates the undesirable audible door slap noise in cable operated, and, particularly, in some electric actuated systems, by reducing door acceleration/speed prior to reaching the end of travel. By providing for a door decelerator system with a rib or similar wall or ridge separate from the lever, and, preferably, a flexible part of the lever, the door is brought gradually to a stop without undesirable noise in the system.

This application claims priority of provisional application 60/641,575 filed Jan. 5, 2005

FIELD OF THE INVENTION

The present invention relates to HVAC units and noise problems due to mechanical parts in such units.

BACKGROUND OF THE INVENTION

In HVAC units using actuators for doors, doors, when closing, can cause a substantial about of ‘noise’ or audible sounds undesirable for the consumer in an air conditioned automotive unit. For example, current cable operated HVAC door technology does not incorporate a mechanism to reduce door acceleration to prevent door audible noise when it contacts the sealing surface. Most HVAC kinematics designs today utilize electric actuated kinematics where the door speed is managed at a constant speed with the actuator to mitigate door audible noise.

One solution to the noise problem used in the past was to over mold foam on the door as a dampener to mitigate door slap noise. In fact, a number of HVAC door designs today, are using over molded santoprene architecture. This design is more conducive to having audible door noise at the end of travel of the door as there is plastic to plastic contact (door and sealing surface), thus, there is still a need to find a mechanism to mitigate or reduce the noise to less audible levels to comply with consumer desires.

In the prior art, for example, when doors that turn or rotate around an axis need to be stopped at a certain point, pieces have been provided with surfaces at the end points modified to stop further movement and to eliminate the door from turning to far and hitting or slapping a wall or other feature, with its accompanying element of noise.

Others features have described that immobilize a body that turns or rotates around an axis, such as in FR 2 803 054 A1, and stops the movement before it gets to an angular immobilization position. By putting a tab or finger on the rotating body itself, the tab or finger can be displaced in such a way that the finger does not contact the cam or others features, or otherwise slow down its movement until it reaches the extreme end of its trajectory.

Other solutions to the noise problem have attempted to mitigate or reduce noise of parts, however, a constant deceleration method of the type herein below, has not been described in the prior art.

SUMMARY OF THE INVENTION

The present invention addresses the need for a door decelerator design to mitigate door audible noise at the end of travel of the door and or its components.

The present invention relates to a door decelerator system which essential eliminates the undesirable audible door slap noise in cable operated, and, particularly, in some electric actuated systems, by reducing door acceleration/speed prior to reaching the end of travel. In both cases a door decelerator system can improve the HVAC system noise by eliminating door audible noise at the end of travel.

The door decelerator system, preferably, reduces the door acceleration and/or speed as it arrives at the end of its travel (the point where the door should not suppress if functioning in accordance with the specification of the vehicle HVAC), against the sealing surface normally found at the end of travel, said sealing surface found inside the HVAC housing. The present invention, by reducing the door speed/acceleration, and particularly in a constant manner, prevents or greatly reduces an audible noise as a result of door contact with the sealing surface inside the housing at a high rotational speed. By a constant manner, it is meant in a manner whereby door deceleration occurs throughout most of, or, preferably essentially all of, the travel of the door from initial position to final stopped position. The door, is, preferably, constantly decelerated prior to reach the end of its travel or contacting the sealing.

The present invention, in its preferred embodiments, reduces audible noise in a process comprising: initially contacting the decelerator lever flexible arm with a first makes compression rib or ribs; slowly deflecting the decelerator lever flexible arm against one or more of the compression ribs until it is fully compressed, thereby reducing the rotational velocity of the decelerator lever and door pivoting about door axis; and fully deflecting the lever decelerator flexible arm is as the door reaches the end of its travel. By following these steps, the door contact with the sealing surface noise is mitigated resulting in minimal audible noise.

In more preferred embodiments of the present invention, a so called door decelerator input/output system is employed. The present invention, in more preferred embodiments, uses a kinematic system to activate the door inside the HVAC housing. In even more preferred embodiments, the door inside the HVAC housing is actuated via a system kinematics comprised of the following: a control head, operated by the vehicle driver and/or passenger; an actuator/cable inputted from the control head; a cam inputted from actuator cable; a decelerator lever inputted from cam movement via cable or actuator; an HVAC door inputted from decelerator lever; and a door sealing surface at the end of travel position of the door.

In preferred embodiments of the present invention, the friction of door decelerator parts occurs throughout most of, or preferably essentially all of, the travel of the door from initial start to final stop position. In more preferred embodiments of the present invention the friction and/or accompaying deflection between a decelerator lever flexible arm (the ‘arm of the decelerator lever’) and a compression rib, occurs along the entire path of travel of the door as it moves from initial start to final stop position.

BRIEF DESCRIPTION OF THE DRAWINGS

The figures show perspective views of HVAC units with door decelerator, both flexible and inflexible, with lever engaged and disengaged with at least one door decelerator part.

FIG. 1 illustrates a cross-sectional view of an HVAC unit, showing door, door decelerator consisting of a lever with arm and rib at the beginning of door movement initial lever and rib contact, in accordance with an aspect of the present invention.

FIG. 2 shows a cross-sectional view of a door decelerator with deformable or flexible lever during the deceleration process, in accordance with an aspect of the present invention.

FIG. 3 shows a door decelerator with deformable or flexible lever at full deflection, in accordance with an aspect of the present invention.

FIG. 4 shows a door decelerator with deformable or flexible lever and rib and HVAC door in accordance with an aspect of the present invention.

FIG. 5 shows a cross-sectional view showing how the door deflector consisting of a rib and lever respond in response to cable or activator signals move the door.

PREFERRED EMBODIMENT OF THE PRESENT INVENTION

In preferred embodiments of the present invention, a door decelerator system is presented which reduces door acceleration/speed to prevent audible door noise in HVAC system. In preferred embodiments of the present invention, a door decelerator comprised of at least one first part and at least one second part can be incorporated as part of the kinematics lever or, preferably, separately, if the HVAC architecture does not allow, for example, the decelerator to be incorporated in the drive levers and systems where direct drive electric actuators without levers are used. In particularly preferred embodiments of the present invention, the door decelerator system consists of the door decelerator rib or wall or projection, and lever and other parts of the HVAC unit, the door decelerator rib or wall or projection (rib) consisting of a flexible or rigid rib or wall, more preferably, rigid, rib or other projection like a rib, that can be used as a door stop by decreasing the flexible mechanism of the decelerator system (flexible lever/flexible compression rib, more preferably semi-flexible or inflexible rib, even more preferably largely inflexible rib, stop).

In preferred embodiments of the present invention, a door decelerator system is provided that reduces or prevents undesirable limits of audible door noise in an HVAC unit, having: a door; a kinematics lever; a door decelerator consisting of at least one first part and at least one second part; wherein the door decelerator at the least one first part is physically separate from the at least one second part, and wherein the at least one first part is incorporated in, attached to or part of the kinematic lever. Also provided is wherein a connection or door lever deceleration axis common between the lever and the door exists. In preferred embodiments, the door decelerator at the least one first part is physically separate from the at least one second part, and wherein the at least one second part is incorporated or attached to or is part of the housing of the HVAC unit.

In more preferred embodiments of the present invention, the door decelerator uses a flexible arm, together with a compression rib, to reduce the door lever acceleration i.e. provide slowdown of the door in such a fashion that undesirable audible noise at the end of its path is reduced or eliminated. In preferred embodiments of the present invention, the flexible part of the lever contacts the compression rib, and the lever is slowly compressed and friction between the two is provided as it reaches the end of travel. Though the lever can be flexible or non-flexible, it is preferably flexible. In preferred embodiments of the present, through use of this system, door speed can be reduced, and less effort used, prior to the end of the travel of the level/door, thereby preventing an undesirable audible door slap noise, without the need of an addition cut out or feature either on the door itself or the cam. The compression rib, preferably, found on the interior surface of the HVAC, therefore provides for a constant, progressive deceleration of the door prior to it reaching the end of its specified trajectory. The door decelerator parts, in preferred embodiments, are incorporated together with the door actuation lever or, in cases where the door is directly driven by an actuator, and, more specifically, electrically, at least one part is separate from a direct actuation lever. By using such a system of door decelerator in the HVAC unit, the decelerator can act as a soft door stop to prevent door over travel or inappropriate final location of the door.

In more preferred embodiments, the at least one second part is a semi flexible or rigid wall or rib. Also more preferred is a door decelerator system wherein the kinematic lever has a branch or arm, and even more preferred wherein the kinematic lever branch or arm is semi-flexible or flexible.

In even more preferred embodiments of the present invention, the door and its deceleration work by the method of actuation and deflection of a flexible door lever against a compression rib. Deceleration is based on actuation and deflection, preferably manual or non-manual or electronic, of a flexible door lever against a compression rib. As the flexible door lever is actuated from one extreme (initial start) to another (final stop) position (fully open/fully closed), it will deflect against a rigid or semi-rigid or flexible compression rib, preferably a rigid or semi-rigid compression rib, prior to the door reaching its normal end of travel, and continues to deflect until the door intended end of travel position is reached.

The door decelerator system can, preferably, also have an electric lever actuator.

In the even more preferred embodiments, the deflection of the flexible door lever acts as a soft or constant brake or deceleration, allowing the door to reduce acceleration and speed prior to reaching the final sealing, end or final stop position, and prevent an undesirable audible door slap noise.

Also provided in the present invention are methods for reducing audible noise in an HVAC unit having doors and for directing or deflecting or blending air, and a decelerator system, said doors being driven by a system with levers, where audible noise is reduced by: contacting a decelerator lever flexible arm initially with a compression rib or ribs; deflecting the decelerator lever flexible arm constantly against one or more of the compression ribs until it is fully compressed; reducing the rotational velocity of the decelerator lever and door pivoting about door axis through while the ribs are being compressed; and deflecting the lever decelerator flexible arm fully is as the door reaches the end or stop position of its travel. In more preferred embodiments of the present invention, constant friction across a surface of contact between the compressor rib and the lever reduces the velocity of the decelerator lever from immediately after start of door pivoting movement until the end or stop position of its travel. Also preferred is an a door input/output decelerator system having a kinematic system including an HVAC door, the kinematic system activating the HVAC door inside an automotive HVAC housing comprising: a control head, operated by the vehicle driver and/or passenger; an actuator or cable inputted from a control head; a cam inputted from the actuator or cable; a decelerator lever inputted from cam movement via the actuator or cable; an HVAC door inputted from a decelerator lever which works together with the door; a compression rib providing friction with the decelerator lever; and a door sealing surface at the end of travel position of the door; wherein the door input/output system decelerate the speed or the velocity of the door from a position of open or closed door to closed or open door in a constant manner after its initial starting point until its final end point with a minimal amount of audible noise occurring when the door reaches its final end point.

FIG. 1 shows the door decelerator, comprising lever and rib in HVAC unit during initial contact of the lever with rib. FIG. 2 shows the door decelerator comprising lever and rib in HVAC unit during deceleration process after initial contact. FIG. 3 shows the door decelerator comprising lever and rib in HVAC at full deflection (end or final stop position in door moving process). M illustrates cam movement with movement from mode cable.

Illustrated in FIGS. 1-3 is a door decelerator system to reduce door (600) acceleration/speed as it moves from open to closed position via, for example, a control head input to cable (300) to cam (920) to decelerator lever (100) and finally to the door (600).

Door speed/accelerator prior to door (600) contact with door sealing surface (400) inside the HVAC housing (500) at high rotational input from vehicle control head (not shown) to the mode cable (940) is illustrated.

Deflection/friction between the decelerator lever flexible arm (100) against the compression rib (300) occurs, with an initial contact of decelerator lever flexible arm (100) with compression rib to impede at same level, door rotation as the decelerator lever makes contact with the compression rib (300).

Decelerator lever flexible arm (100) slows down the rotational velocity of the door as it slowly deflects against compression rib (300) until the door reaches the sealing surface (400).

Door (600) velocity will be at a minimum as it makes contact with the door sealing surface (400) and decelerator lever flexible arm (100) will be at maximum deflection.

Referring to FIG. 1, compression rib (300) and decelerator lever arm (200), which is preferably flexible, have initial contact at (330) as door (600) approaches sealing surface (400). Decelerator lever (100) is shown with drive pin (800). Preferably, drive pin (800) receives input from cam (920), lever and door having pivot point (700). Cam slides in cam track (900). Cam (920) movement can be driven with input from mode cable (940). Mode cable (940) can have input from vehicle control head (not shown). Door sealing surface (400), showing (500) with door in open position (600) is shown.

Referring to FIG. 2, compression rib (300) and decelerator lever arm (200), which is preferably flexible are shown with lever flexible arm contacting rib from initial contact to final stop position at the region around area (360). Door (600) approaches and eventually reaches, sealing surface (400).

Decelerator lever (100) is shown with drive pin (800). Preferably, drive pin (800) receives input from cam (920), lever and door having pivot point (700). Cam slides in cam track (900). Cam (920) movement can be driven with input from mode cable (940). Mode cable (940) can have input from vehicle control head (not shown).

Door sealing surface (400) shown on housing (500) with door in closed position (660) is shown.

Referring to FIG. 3, compression rib (300) and decelerator lever arm (200), which is preferably flexible, are shown, with decelerator lever arm at full deflection in area (390) with compression rib (300) when door (600) reaches sealing surface (400).

Decelerator lever (100) is shown with drive pin (800). Preferably, drive pin (800) receives input from cam (920), lever and door having pivot point (700). Cam slides in cam track (900). Cam (920) movement can be driven with input from mode cable (940). Mode cable (940) can have input from vehicle control head (not shown).

Door sealing surface (400) shown on housing (500) with door in closed position (660) is shown.

FIG. 4 illustrates an HVAC door (1600) with door decelerator area (1500) shown. Rib (1300) is in contact with lever (1200) and sealing surface (1400) is shown on door.

Referring to FIG. 5, is a cross sectionally schematic view of a preferred embodiment of the present invention employing more than one first and/or second parts of the door decelerator. An HVAC unit (2700), having two lever arms (2200(a)) (2200(100)) in various positions, and placement of compression ribs (2300) depending on closing needs of doors. Distribution area (2000) is also shown.

Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure. Alternatively, a single integrated structure might be divided into separate plural components. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention.

The preferred embodiment of the present invention has been disclosed. A person of ordinary skill in the art would realize however, that certain modifications would come within the teachings of this invention. Therefore, the following claims should be studied to determine the true scope and content of the invention. 

1. A door decelerator system to reduce or prevent undesirable limits of audible door noise in an HVAC unit, having: a door; a kinematics lever; a door decelerator consisting of at least one first part and at least one second part; wherein the door decelerator at least one first part is physically separate from the at least one second part, and wherein the at least one first part is incorporated in, attached to or part of the kinematic lever.
 2. A door decelerator system is to reduce or prevent undesirable limits of audible door noise in an HVAC unit, having: a door; a kinematics lever; a connection or door lever deceleration axis common between the lever and the door; and a door decelerator consisting of at least one first part and at least one second part; wherein the door decelerator at least one first part is physically separate from the at least one second part, and wherein the at least one second part is incorporated or attached to or is part of the housing of the HVAC unit.
 3. A door decelerator system as in claim 2, wherein the at least one first part is incorporated or attached to or is part of the kinematic lever.
 4. A door decelerator system as in claim 3, wherein the second at least one part is a flexible, semi-flexible or rigid wall or rib.
 5. A door decelerator system as in claim 4, wherein the at least one second part is a semi-flexible or rigid wall or rib.
 6. A door decelerator system as in claim 5, wherein the system is used as a door stop mechanism.
 7. A door decelerator system as in claim 2, wherein the kinematic lever has a branch or arm.
 8. A door decelerator system as in claim 7, wherein the kinemetic lever branch or arm is semi-flexible or flexible.
 9. A door decelerator system as in claim 3, wherein the kinematic lever has a branch or arm.
 10. A door decelerator system as in claim 9, wherein the kinematic lever branch or arm is semi-flexible or flexible.
 11. A door or decelerator system as in claim 10, wherein the at least one second part is a semi-flexible or rigid wall or rib.
 12. A door or decelerator system as in claim 11, wherein there is more than one second part.
 13. A door decelerator system as in claim 5, further comprising an electric lever actuator.
 14. A door decelerator system as in claim 13, wherein the lever in the area of the lever branch or arm is flexible and the wall or rib is rigid.
 15. A method for reducing audible noise in an HVAC unit having doors and for directing or deflecting or blending air, and a decelerator system, said doors being driven by a system with levers, where audible noise is reduced by: contacting a decelerator lever flexible arm initially with a compression rib or ribs; deflecting the decelerator lever flexible arm constantly against one or more of the compression ribs until it is fully compressed; reducing the rotational velocity of the decelerator lever and door pivoting about door axis through while the ribs are being compressed; and deflecting the lever decelerator flexible arm fully is as the door reaches the end or stop position of its travel.
 16. A method as in claim 15, wherein constant friction across a surface of contact between the compressor rib and the lever reduces the velocity of the decelerator lever from immediately after start of door pivoting movement until the end or stop position of its travel.
 17. A door input/output decelerator system having a kinematic system including an HVAC door, the kinematic system activating the HVAC door inside an automotive HVAC housing comprising: a control head, operated by the vehicle driver and/or passenger; an actuator or cable inputted from a control head; a cam inputted from the actuator or cable; a decelerator lever inputted from cam movement via the actuator or cable; an HVAC door inputted from a decelerator lever which works together with the door; a compression rib providing friction with the decelerator lever; and a door sealing surface at the end of travel position of the door; wherein the door input/output system decelerate the speed or the velocity of the door from a position of open or closed door to closed or open door in a constant manner after its initial starting point until its final end point with a minimal amount of audible noise occurring when the door reaches its final end point. 